Mathematical Modelling and Simulation of

The objective of this study was to analyze the fluid flow of molten steel in a continuous casting tundish using numerical simulations for better inclusion floatation and its separation. The tundish geometry was designed using Autodesk FUSION 360 and the analysis was performed on ANSYS FLUENT. The investigations were conducted under steady-state and transient conditions. To reduce vortexing and turbulence within the tundish, turbo stoppers and flow modulators, such as dams and weirs, were strategically placed to achieve optimized and efficient flow. The placements of these flow modifiers resulted in heightened turbulence in the recess region, promoting a more homogeneous fluid flow and improved conditions for particle separation. The flow behavior analysis employed particle tracking methods within a dense discrete phase modeling framework alongside a multiphase Eulerian-Lagrangian model. Notable reductions in dead volumes and metal loss were achieved due to enhanced intermixing, leading to increased yield. Additionally, studying the eddy formations elucidated the flow-induced shear distribution, resulting in diminished turbulence on the liquid steel surface, thereby reducing the loss of liquid steel quality.